Genius NEMA4 I/O Station, IC660BXD0022, GFK-0832
Contents
1. cable connect a terminating resistor of the appropriate type see the System and Communications User s Manual across its Serial 1 and Serial 2 terminals 4 GFK 0832A Connecting I O Devices Connect I O devices to the Brad Harrison style connectors in the side of the housing Each connector can be used for an input or output Note To avoid possible contamination leave covers on unused connectors Wiring for Tristate Inputs If any input is configured as a Tristate Input it will be necessary to install a 1 6K ohm resistor across that circuit s input and 24 volt terminals inside the housing This added resistance is required to use the Open Wire diagnostic The circuit LED will glow dimly Dual Input or Output Connection Dual input and output devices require a simple change to the factory wiring inside the housing A dual input or output device uses one connector in the housing but counts as two circuits on the I O block For practical purposes these two circuits should be located near each other on the wiring board see the diagram at the bottom of the page 1 Be sure power to the I O Station is OFF before proceeding 2 Decide on two circuits to use for the device For example 7 and 9 3 Install the dual input or output device at the housing connector for either of the two selected circuits Keep the connector for the other circuit covered Caution Be sure no device is installed on the connector that cor2. 0 Operating Ambient Temperature Degrees C
3. GFK 0832A June 1994 The NEMA4 I O Station consists of a 24 VDC Source I Oblock installed ina rugged aluminum NEMA4 housing The block is pre wired to receptacles in the housing for simple connection of field wiring Block Features The block in the I O Station can be used with 2 wire and 3 wire solid state sensors and electromechanical sensors It has 16 discrete circuits each easily configured to be an input tristate input or output Output circuits can be connected directly to input circuits without the use of other components or inversion of logic states The block s LEDs verify proper block operation and CPU communications Individual circuit LEDs on the logic side indicate voltage present on inputs and outputs Housing Features The I O Station s NEMA4 housing provides a measure of protection against falling splashed and hose directed water It can be used indoors or outdoors The block will not be damaged by the formation of ice on the housing I O connections to the block are made through the housing via Brad Harrison style molded receptacles Communications and power cables are installed via pass through water tight connectors The housing has a transparent window in the cover so the block s LEDs can be seen I OProducts NEMA4 I O Station IC66 BXD022
4. ar the wiring board we D Ground wire to I O block Attach optional outgoing Ti Attach incoming ground wire here ground wire here If you are daisy chaining the power cable out to another device connect the ground wire of the outgoing power cable to the remaining ground terminal 3 GFK 0832A Power Connections Using two quick disconnects attach the incoming power wires to the wiring board as shown below Re l Attach incoming gt 24V wire here gll pa T Attach incoming O common wire here If you are daisy chaining the power cable out to another device connect the outgoing power wires o Power Disconnects Wire external power disconnects so that block power and input power will be removed at the same time Caution If circuit power is not removed at the same time as block power the block may power up when multiple inputs are activated even though one leg of power has been removed from the block Serial Bus Connections Connect the incoming serial bus to terminals 1 3 on the I O block as shown below If there is also an outgoing bus cable connect it to terminals 1 2 and 4 Recommended torque for the terminal screws is 6in Ib 678N M oy o o o 112 SERIAL 1 2 2 SERIAL 2 3 SHIELD IN 4 Serial Optional Bus In Serial Bus Out If the station is at the end of the bus no bus out
5. at the base of the Terminal Assembly and electrical shock hazard exists Do not touch the connector pins Death or injury may result NEMA4 I O Station Inserting the Electronics Assembly 1 Alignthe Electronics Assembly within the guides and push it down firmly Do not exert excessive force it may damage the block If unusual resistance is met remove the Electronics Assembly If power is applied to the block DO NOT TOUCH THE CONNECTOR PINS Inspect the Terminal Assembly connector receptacle and connector edge board on the Electronics Assembly Remove any obstacles and reinsert the Electronics Assembly Pay close attention to the alignment of the guide pins 2 Secure the Electronics Assembly with the retaining screws Removing the Block 1 Disconnect power to the I O station and remove the housing cover 2 Remove the wiring from the Terminal Assembly 3 Using a Phillips head screwdriver unscrew the mounting screws at the top and bottom of the block Mounting screw Olo top of block 4 Carefully remove the block Reverse the procedure to replace the block After replacing the block re install the wiring Wiring follows standard color code convention The block must be reconfigured see next page for a brief explanation before it can operate on the communications bus NEMA4 16 Circuit DC Source I O Block I O Block Information Summary Each circuit on the I O block can be configu
6. disabled disabled Note If the block is configured offline it must be properly yorman and have a 75W resistor installed across its Serial and Serial 2 terminals See the Discrete and Analog Blocks User s Manual for instructions Compatibility Any Hand held Monitor can be used with the NEMA4 I OStation However version IC66 HHM501 is required to change baud rate configuration or to configure the block for redundancy For an IC697 series PLC the CPU and programming software must be version 2 0 or later The bus controller must be IC697BEM731C or later For an IC600 series PLC the CPU must be rev 105 or later For an IC66 series Plus PLC rev 110 or later is required The programming software must be rel 4 02 or later If the bus controller is model IC66 CBB900 it must be version C or later For an IC550 series PLC the CPU must be rev 3 0 or later The programming software must be rel 2 01 or later 8 GFK 0832A I O Station Specifications NEMA4 I O Station Pass through current Catalog Numbers NEMA4I OStation IC66 BDX022 24VDC Source 16 Circuit Source I O Block 1C66 BBD022 Terminal Assembly only 1C66 TBD022 Electronics Assembly only IC66 EBD020 I O Station Size height x width x depth 10 13 in 257 3 mm x 7 63 in 193 8 mm x 5 50 in 139 7 mm LEDS block UnitOK I OEnabled LEDs each circuit Individual load side indicators HeatDissipation tbd Block to Block Isolation 1500 V Operating voltag
7. e 18 56 VDC 24 48 V 18 30 VDC 24 V Ripple maximum 10 Required DC power 150mAtypical 300mAmaximum Power supply dropout time 10mS 15 Amps minus the power used by the I O block and the devices connected to the I OStation InputCharacteristics For standard input voltage relative to DC Input processing time typical Input impedance typical Selectable input filter times Inputdiagnostics Input ON 16 24 VDC Input OFF 0 7 VDC 5 6K ohms 24 48V 1 8K ohms 24V 1 7mS plus selectable filter delay 5 100mS Open wire Overtemperature Failed Switch OutputCharacteristics Output current steady state 2 amps per circuit Maximuminrush current 10 amps up to 10mS Block output current 15 amps at 35C Output OFF leakage current 1 0mA Maximum switching frequency Once per second high inrush current Output turn on delay maximum 1ImS Output voltage drop 2 0 volts maximum at 2 amps inrush Minimum Recommended Load 50 mA with No Load nabled Output Diagnostics Short Circuit Overload No Load Failed Switch Overtemperature Environmental Operating temperature tbd Storage temperature 40 to 100C 40 to 212F Humidity NEMAenclosure Vibration 5 10Hz 0 2 5 08mm displacement 10 200Hz at 1G Temperature Derating The illustration below shows total load current versus temperature derating for the NEMA4 I O Station 16 Total Station 12 Load 8 Current Amps 4 0 10 20 30 40 50 6
8. e the same func T 24V tion For example the In Out terminals for 24V gt N C even numbered circuits 2 to 16 are in the gt COM gt same row IN OUT 4 6 8 10 12 14 16 NEMA4 16 Circuit DC Source I O Block 5 GFK 0832A Install the first black wire you removed on the NC terminal where you removed the white wire 7 9 i IN OUT COM replace black N C wire here Pa ae 24V 6 GFK 0832A Block or Terminal Assembly Removal The block s Electronics Assembly can be removed and replaced without removing field wiring or reconfiguring the block If you remove the entire block it will be necessary to remove the wiring and to reconfigure the block Removing the Block s Electronics Assembly 1 Disconnect power to the I O station and remove the housing cover 2 Using a Phillips head screwdriver unscrew the Electronics Assembly retaining screws at the top and bottom of the block Retaining screw for Electronics Assembly oe top of block 3 Using the special I O Station Block Puller engage the tabs in the first vent slots 4 Pull the Electronics Assembly upward a Vent Slots i a Electronics Assembly Retaining P Screws er L j Qty 2 p Terminal i s BEY Assembly E LEE Connector Pins If power is applied to the field terminals power is also exposed on the connector pins
9. n so that the notches in the flanges line up with the mounting holes Mount the block using 10 screws Use star washers to provide ground integrity a45353 5 50 in 139 70mm iam Ca ha 4 28 in 108 7mm NEMA4 16 Circuit DC Source I O Block Power and Bus Connections Power and bus cables must be 0 25 to 0 375 in diameter The power cable must include a ground wire to bring chassis ground into the module Three to six 250 x 032 female quick disconnects are required Note The IO Station can be located on a bus stub downstream of another device that performs bus switching It cannot be directly connected to a dual bus Remove the housing cover to begin cable installation After installation the housing cover must be firmly installed on the base Recommended screw torque is 12 in lbs Cable Installation Pass the incoming serial bus and power cables through connectors SI and PI on the housing bottom Connectors SO and PO can be used to daisy chain the bus andr power cable to another device To use either of these connectors first loosen the nut and remove the plug a45352 7 S CER Plug Caution Tighten the connector nuts firmly around all bus and power cables before completing the installation GroundConnections Using a quick disconnect attach the power cable ground wire to the ground terminal ne
10. red as an input a tristate input or an output If the block is configured as a combination block output feedback is provided via the corresponding input references All output devices connect to the negative side of the power supply Inputs control the positive side DC Z rn 4 DC Configured Input Y as an Device A 75V Intput P 1216 K Smarta gt f vO i 4 Switch Processor Configured f i ASAN Output x Device aS N Output Th 1ufd LED 12000 ae lt Dc Field Terminal Electronics Connections Assembly Assembly 5 6K ohms for 24 48 VDC blocks 1 8K ohms for 24 VDC blocks Circuit LEDs Each circuit has its own LED If the circuit is configured as an input the LED indicates the presence of threshold voltage at the input terminal If the circuit is configured as an output the LED indicates the actual state of the load Diagnostics The block reports all faults to the Hand held Monitor and takes appropriate corrective action Short Circuit Diagnostic standard Instantaneous current exceeds 10 amps at turn on m Overtemperature Diagnostic standard Internal temperature exceeds 100 C m Failed Switch Diagnostic standard Output switch state is not the same as its commanded state May also indicate certain internal block faults m Open Wire Diagnostic standard Electrical not mechanical malfunction on a
11. responds to the other circuit of the pair Unexpected operation would result 4 On the wiring board make the following changes Note Using long nose pliers grasp wires by the crimped terminal in the strain relief area ONLY 3 5 7 9 1 NEMA4T O Station First remove the black wire from theIn Out terminal corresponding to the unused circuit For example if 9 were not used 7 9 remove black wire n a IN OUT COM N C 24V l f 5 Continue below for a dual output or input For a Dual Output Remove the brown wire 24V from the other terminal of the pair Install it on the In Out terminal where you removed the first black wire 2 replace brown 7 Bs wire here 1 remove INONT brown wire N C here 24V Install the first black wire you removed on the 24V terminal where you removed the brown wire 7 9 i IN OUT COM replace black S N C wirehere gt 24V For a Dual Input Remove the white wire No Connect from the other terminal of the pair Install it on the In Out terminal where you removed the first black wire 2 replace white 7 2 wire here T IN OUT COM N C 24V 1 remove white wire here _ fj 13 15 Terminals on the Wiring Board gt IN OUT There are 4 terminals for each I O circuit gt COM In Out Common No Connect and 24V gt N C All terminals in a row hav
12. tristate input m Overload Diagnostic configurable No Load Diagnostic configurable Configuration The block must be configured with an HHM to m Enter its Block Number serial bus address m Enter its Reference Number required only for IC550 and IC600 series PLCs only 7 GFK 0832A In addition unless all circuits on the block will be inputs the Block I O Type must be set to either Outputs or Combination on the Program Block ID screen Explosion Hazard DO NOT connect a Hand held Monitor to the block during operation in a CSA Class 1 Div 2 location The features below can be configured from an HHM see the Discrete and Analog Blocks User s Manual for instructions or the application program as detailed in the System and Communications User s Manual Configurable Circuit Selection Factory Feature or Setting Block BlockI OType B inputs outputs combination inputs Baud Rate B 153 6st 153 6ex 76 8 38 4 Kb 153 6st Pulse Test B enabled disabled enabled Input Filter Time B 5 100mS 20mS CircuitI OType C input output tristate input input Report Faults C yes no yes Hold Last State C yes no no Output Def State C on off off Detect No Load C yes no yes Overload S down C yes no yes BSM Present B yes no no Outputs Def Time B 2 5 10seconds 3 bus scans Redundancy Mode B none duplex standby GMR none Duplex Default B on off off Config Protect B enabled
13. ye N 4On GE Fanuc adie DH DH Dp Vg P DA a eo CX cen 5 A a45351 Wor KC Using this Datasheet This datasheet describes installation of the IO Station It also briefly summarizes information about the operation configuration and diagnostics features of the I O block If you need more information about the IO block please see the Discrete and Analog Blocks User s Manual GEK 90486 2 For information about systems and communications including bus specifications refer to the System and Communications Manual GEK 90486 1 2 GFK 0832A Mounting the I O Station The illustration below shows m overall dimensions of the I O Station m mounting hole spacing m wiring clearances required from the side and bottom of the housing to a wall panel or other obstruction Side Clearance a 2 70 in gt a Mounting Hole Spacing 7 31 in p 68 6mm 185 7mm a N Mounting Hole Spacing _ 8838in Module Height 225 6mm p 10 13in p 257 3mm a 7 13 in gt Module Width 181 1mm Bottom Clearance 4 3 70 in 94mm Equipment Required q NEMA4T O Station Quantity 4 10 mounting screws Mount the block in the orientation shown below Drill screw or bolt holes for 10 hardware Position the statio
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